Flip pack switch assembly with electroluminescent lamp and injection molding method of making same

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to U.S. patent application Ser. No. 10/711,462 filed Sep. 20, 2004, now pending in the U.S. Patent and Trademark Office and U.S. patent application Ser. No. 10/711,463 filed Sep. 20, 2004, now pending in the U.S. Patent and Trademark Office and U.S. patent application Ser. No. 10/711,480 filed Sep. 21, 2004, now pending in the U.S. Patent and Trademark Office and U.S. patent application Ser. No. 10/711,636, filed Sep. 29, 2004, now pending in the U.S. Patent and Trademark Office, and U.S. patent application Ser. No. 10/711,652 filed Sep. 29, 2004, now pending in the U.S. Patent and Trademark Office.

FIELD OF THE INVENTION

The present invention pertains generally to automotive interiors and more particularly to flip pack switch assemblies for automotive interiors.

BACKGROUND OF THE INVENTION

Vehicle door constructions typically feature a metal door frame with a sheet metal outer panel or skin that defines the door's exterior and an inner sheet metal panel secured to the door frame. Various door components, including window regulator rails, audio speakers, latches, and the like, are fastened in openings defined in the inner sheet metal panel. Covering the inner door panel is a removable trim panel that provides an aesthetically pleasing facade viewed by occupants seated in the passenger cabin of the motor vehicle. Controls are provided on the trim panel for devices such as seats, door locks, mirror and windows. The door latch is connected by a cable to an inner release handle on the trim panel accessible to the vehicle occupant.

Electrical switches may be provided on the door trim panel that operate the power door locks, adjust the passenger seats, open and close vehicle windows, and adjust the side view mirrors. In one type of construction, the electrical switches are arranged in a flip pack having a stationary switch panel and a hinged cover joined with the switch panel. The switch panel carries electrical switches that are infrequently used, such as seat switches, and the hinged cover carries electrical switches that are more frequently used, such as window switches. Normally, the hinged cover is pivoted to cover the switch panel so that the more frequently used electrical switches carried by the cover are visible. To access the less frequently used electrical switches, the cover is pivoted to reveal the electrical switches on the switch panel.

The electrical switches on the cover are illuminated with multiple discrete point light sources, such as light emitting diodes or incandescent bulbs, in the bolster that are aimed at different portions of the upper surface of the cover so as to uniformly illuminate the electrical switches. Similarly, the underside of the cover includes multiple discrete point light sources that are aimed at different portions of the switch panel. The illumination from the point light sources makes the electrical switches more visible under low-lighting conditions, such as early evening or dusk, and darkness caused by storms during the daytime and the like. However, this type of lighting construction requires a large number of components in an intricate assembly. Moreover, the aimed beams of the point light sources may be blocked by a person's hand when the switches are manually actuated so that the advantage gained by lighting the electrical switches of the flip pack is lost.

What is needed therefore is a lighting construction for flip panels that improves on conventional lighting constructions for flip packs.

SUMMARY OF THE INVENTION

In an embodiment of the invention, an automotive interior component comprises a door trim panel including a switch panel carrying at least one electrical switch, a flip cover pivotally attached to the switch panel, and a electroluminescent lamp mounted to the flip cover. The door trim panel is capable of being mounted to the vehicle door. The flip cover has an opened position in which the electrical switch is accessible and a closed position in which the electrical switch is inaccessible. The electroluminescent lamp is positioned for emitting visible light, when powered, to illuminate the electrical switch on the switch panel when the flip cover is in the opened position.

In another embodiment of the invention, a method is provided for making an automotive interior component in a mold with a pair of half sections that form a mold cavity with a geometrical shape resembling a flip cover for a flip pack and a gate for filling the mold cavity. The method includes placing an electroluminescent lamp between the half sections of the mold, closing the mold half sections and injecting a molten polymer resin through the gate to fill a portion of the mold cavity unfilled by the electroluminescent lamp, and opening the mold half sections after the molten polymer resin solidifies and ejecting the automotive interior component having the geometrical shape of the flip cover from the mold.

These and other objects and advantages of the invention shall become more apparent from the accompanying drawings and description thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention.

<figref idref="DRAWINGS">FIG. 1</figref> is a perspective view of a door trim panel fastened to a vehicle door frame and including a flip pack of the present invention;

<figref idref="DRAWINGS">FIG. 1A</figref> is a diagrammatic view illustrating the electrical circuit for the electroluminescent lamps of the invention;

<figref idref="DRAWINGS">FIG. 2</figref> is a view similar to <figref idref="DRAWINGS">FIG. 1</figref> in which the cover of the flip pack is pivoted to an opened position;

<figref idref="DRAWINGS">FIG. 3</figref> is a cross-sectional view of the cover of <figref idref="DRAWINGS">FIG. 2</figref>;

<figref idref="DRAWINGS">FIG. 3A</figref> is a detailed view of a portion of <figref idref="DRAWINGS">FIG. 3</figref>;

<figref idref="DRAWINGS">FIGS. 4-6</figref> are diagrammatic cross-sectional views illustrating a molding process for forming the flip pack of the present invention; and

<figref idref="DRAWINGS">FIG. 7</figref> is a view of a flip pack in accordance with an alternative embodiment of the invention.

DETAILED DESCRIPTION

With reference to <figref idref="DRAWINGS">FIGS. 1 and 2</figref>, a door trim panel <b>10</b> constructed in accordance with an embodiment of the invention is shown fastened to a door of a vehicle such as, for example, an automobile, a truck, or an aircraft. More specifically, door trim panel <b>10</b> is coupled as an assembly with the inner sheet metal of a door frame <b>12</b>, which has a hinged attachment with a body of an automobile. The trim panel <b>10</b> may be attached to the door frame <b>12</b> by suitable fasteners (not shown) as is well known in the art. Persons of ordinary skill in the art will appreciate that door trim panel <b>10</b> may be used on other door assemblies including but not limited to sliding doors, hatches, etc. Further, persons of ordinary skill in the art will also appreciate that door frame <b>12</b> may be constructed of other materials such as composites like fiberglass and carbon fibers. A passenger occupying the passenger cabin of the automobile can manually move the assembled door relative to the body for passenger ingress and egress of the passenger cabin.

The door trim panel <b>10</b> includes a bolster <b>14</b> covering an access opening to the open space between the trim panel <b>10</b> and the door frame <b>12</b>, an armrest <b>16</b>, a flip pack <b>18</b> mounted to the arm rest <b>16</b>, a map pocket closeout <b>20</b>, and a speaker grille <b>22</b> that covers an audio speaker (not shown). The flip pack <b>18</b> includes a flip cover <b>24</b> with an upper surface <b>15</b> that carries a plurality of electrical switches <b>25</b> and a switch panel <b>26</b> (<figref idref="DRAWINGS">FIG. 2</figref>) carrying another plurality of electrical switches <b>27</b>. The electrical switches <b>25</b>, <b>27</b> are used to operate powered devices associated with the automobile. For example, the electrical switches <b>25</b>, <b>27</b> may open and close windows, adjust side mirrors, or move power seats. A hidden wiring harness couples the electrical switches <b>25</b>, <b>27</b> with the powered devices. The flip cover <b>24</b> has a hinged coupling with the switch panel <b>26</b>.

Electrical switches <b>25</b> are accessible and electrical switches <b>27</b> are inaccessible to the passenger cabin occupant with the flip cover <b>24</b> in a closed position, as shown in <figref idref="DRAWINGS">FIG. 1</figref>. Electrical switches <b>27</b> are accessed by pivoting the flip cover <b>24</b> to an opened position, as shown in <figref idref="DRAWINGS">FIG. 2</figref>. In the opened position, electrical switches <b>25</b> are inaccessible. The electrical switches <b>25</b> may be more frequently used than electrical switches <b>27</b>, which would preferably result in the flip cover <b>24</b> normally being maintained in the closed position.

With reference to <figref idref="DRAWINGS">FIGS. 3 and 3A</figref> in which like reference numerals refer to like features in <figref idref="DRAWINGS">FIG. 1</figref>, the bolster <b>14</b> further includes an electroluminescent (EL) lamp <b>29</b> that is capable of emitting diffuse light for illuminating the nearby electrical switches <b>25</b>. Similarly, a lower surface <b>17</b> on the underside of the flip cover <b>24</b> carries another EL lamp <b>28</b> that is capable of emitting diffuse light for illuminating the nearby electrical switches <b>27</b> when the flip cover <b>24</b> is pivoted to the opened position. Different lighting effects can be achieved by varying the position of the EL lamps <b>28</b>, <b>29</b> within the flip cover <b>24</b> and bolster <b>14</b>. The EL lamps <b>28</b>, <b>29</b> have an identical construction that will be described below with regard to EL lamp <b>28</b> with the understanding that the description applies equally to EL lamp <b>29</b>.

EL lamp <b>28</b> consists of a stacked structure of multiple layers carried on a suitable flexible structural substrate <b>30</b>. The layered structure includes a layer of an EL phosphor <b>32</b> disposed between substantially parallel front and rear electrodes <b>34</b> and <b>36</b>, respectively. The phosphor layer <b>32</b> is contiguous with the front electrode <b>34</b> but spaced from, and electrically isolated from, the rear electrode <b>36</b> by a dielectric layer <b>38</b>. The front electrode <b>34</b>, which faces into the interior of the passenger compartment, is light transmissive (i.e., transparent or translucent) for transmitting light emitted from the phosphor layer <b>32</b> when an electric field is applied between the front and rear electrodes <b>34</b>, <b>36</b>. The dielectric layer <b>38</b> may be pigmented to supply a dark or colored background for the emitted light.

A protective encapsulation layer <b>40</b> of a light-transmissive substance, such as polycarbonate or another polymer suitable for this application, optionally covers the front electrode <b>34</b> of the EL lamp <b>28</b>. The encapsulation layer <b>40</b> may be applied to the stacked structure as a printed ink layer. An electrical connector <b>42</b>, such as an edge electrical connector, includes power contacts that are coupled with the front and rear electrodes <b>34</b>, <b>36</b>. The power contacts of the electrical connector <b>42</b> are exposed through the encapsulation layer <b>40</b> for establishing electrical contacts. The EL lamp <b>29</b> of bolster <b>14</b> includes an electrical connector <b>43</b> similar or identical in construction and function to electrical connector <b>42</b>.

The layers of the EL lamp <b>28</b> may be printed onto the substrate by rotary screen printing, flexographic printing, or other printing methods using conducting, insulating and electroluminescent ink compositions. The ink compositions are printed across a desired print area on the substrate <b>30</b>, or alternatively on the encapsulation layer <b>40</b>, and then dried to remove volatile solvents for forming stable layers. Some of the layers in the stacked structure may be printed more than once in order to assure proper thickness.

Phosphor ink compositions are available to emit light in many colors, such as green, blue, and yellow, and may also be blended to produce white or colored light emission. Typical EL phosphors for EL lamp <b>28</b> are comprised of inorganic zinc sulfide-based materials doped to create the desired color emission. Suitable EL phosphor ink compositions include white, blue-green and yellow-green LUXPRINT® electroluminescent inks commercially available from DuPont Microcircuit Materials (Research Triangle Park, N.C.).

In one embodiment of the invention, a flexible metallized film may effectively function as the substrate <b>30</b>, the rear electrode <b>36</b> and the dielectric layer <b>38</b> of the EL lamp <b>28</b>. Such metallized films include a thin layer of a metallic conductive material, like aluminum, deposited on one side of a film material, like polyester. The deposited metallic layer operates as the rear electrode <b>36</b> and the film material acts as the dielectric layer <b>38</b>. The metallized film also serves as a substrate <b>30</b> for application of the remaining printed component layers (e.g., phosphor layer <b>32</b> and front electrode <b>34</b>) of the stacked structure.

With reference to <figref idref="DRAWINGS">FIGS. 1 and 1A</figref>, an inverter or converter <b>44</b> electrically couples a direct current (DC) electrical system of the vehicle, which includes the car battery <b>46</b>, with the electrical connectors <b>42</b>, <b>43</b>. The converter <b>44</b> converts the DC voltage from the electrical system to generate an alternating current (AC) driving voltage in the range of 80 to 200 VAC, preferably about 110 VAC, at a frequency in the region of 300 to 500 Hz, preferably about 400 Hz. Additional circuitry, as recognized by persons of ordinary skill in the art, may be provided as required to ensure proper operation of the EL lamps <b>28</b>, <b>29</b>. Application of the AC driving voltage across the front and rear electrodes <b>34</b>, <b>36</b> of the EL lamps <b>28</b>, <b>29</b> generates a varying electric field within the phosphor layer <b>32</b> causing the constituent phosphor particles to emit visible light. In general, the brightness of the EL lamps <b>28</b>, <b>29</b> increases with increased voltage and frequency. Power to the EL lamp <b>28</b> may be switched, for example, in coordination with a switch (not shown) that closes the electrical circuit including EL lamp <b>28</b> when the flip cover <b>24</b> is pivoted to the opened position. Similarly, power to the EL lamp <b>29</b> may be switched, for example, in coordination with operation of a light switch <b>49</b> controlling vehicle lighting.

The EL lamps <b>28</b>, <b>29</b> have a low power consumption and very low heat generation as compared with conventional lamps used in such automotive applications. Furthermore, the EL lamps <b>28</b>, <b>29</b> are sturdy and exhibit excellent vibration and impact resistance. The EL lamps <b>28</b>, <b>29</b> will have a lengthy life and will not normally need replacement over the life of the automobile, in contrast to the need to periodically replace burnt-out conventional incandescent bulbs. The resin material forming the bolster <b>14</b> and the flip cover <b>24</b> need not be heat resistant as the EL lamps <b>28</b>, <b>29</b> have a cooler operating temperature than conventional incandescent bulbs.

With reference to <figref idref="DRAWINGS">FIGS. 4-6</figref>, a method of making the flip cover <b>24</b> with the EL lamp <b>28</b> in a mold cavity <b>58</b> by an injection molding process will be described. The method will apply equally to the molding of bolster <b>14</b> and EL lamp <b>29</b>, other than a change in the shape of mold cavity <b>58</b>.

In <figref idref="DRAWINGS">FIG. 4</figref>, an injection die or mold <b>50</b> having first and second mold sections <b>52</b>, <b>54</b> is provided. The EL lamp <b>28</b> is placed at a specified location between the first and second mold sections <b>52</b>, <b>54</b> so that the power contacts of the electrical connector <b>42</b> (<figref idref="DRAWINGS">FIG. 2</figref>) are exposed after molding for establishing electrical contacts. As shown in <figref idref="DRAWINGS">FIG. 5</figref>, the mold <b>50</b> is closed so that the first and second mold sections <b>52</b>, <b>54</b> define the mold cavity <b>58</b> having the general three-dimensional geometrical shape of the flip cover <b>24</b>.

As shown in <figref idref="DRAWINGS">FIG. 6</figref>, molten resin material is injected by an extruder through one or more gates <b>56</b> into the mold cavity <b>58</b> and fills the space inside the cavity <b>58</b> not occupied by the EL panel <b>28</b>. The synthetic resin material is selected according to the characteristics required for the flip cover <b>24</b> and may be any engineering polymer material suitable for an injection molding process. The injection molding process creates sufficient pressure and heat to bond the EL lamp <b>28</b> and the injected molten resin material to form the flip cover <b>24</b> as an integral structure. The resin material, when solidified, defines a polymer portion <b>55</b> of the bolster <b>14</b>. The mold <b>50</b> is opened by separating the mold sections <b>52</b>, <b>54</b> and the flip cover <b>24</b> is ejected from the mold <b>50</b> in a condition ready for delivery as a unitary component for assembly on an automotive production line.

If necessary, the flip cover <b>24</b> may then either be partially or completely vacuum-or thermo-formed to achieve a final desired shape. In this regard, the shape of the cavity in mold <b>50</b> may not reflect the three-dimensional geometrical shape of the flip cover <b>24</b> as such post injection molding processes may be used to form the final shape.

The invention also contemplates that the article formed by the injection molding process may be the entire trim panel <b>10</b> with an integral bolster <b>14</b> that includes the EL lamp <b>29</b>. In this embodiment, the three-dimensional geometrical shape of the article-forming cavity of the mold <b>50</b> will reflect that of the trim panel <b>10</b> or a post injection molding process is used to shape the molded article to form the final shape of trim panel <b>10</b>.

With reference to <figref idref="DRAWINGS">FIG. 7</figref> in which like reference numerals refer to like features in <figref idref="DRAWINGS">FIGS. 1-6</figref> and in an alternative embodiment of the invention, the trim panel <b>10</b> may be provided with a flip pack <b>18</b><i>a </i>with a flip cover <b>24</b><i>a </i>that lacks the electrical switches of flip cover <b>24</b> (<figref idref="DRAWINGS">FIGS. 1 and 2</figref>) and a bolster <b>14</b><i>a </i>that lacks EL lighting, as present on the upper surface <b>15</b> of the flip cover <b>24</b> (<figref idref="DRAWINGS">FIG. 1</figref>), because of the absence of switches. The underside of the flip cover <b>24</b><i>a </i>is provided with an EL lamp <b>28</b><i>a</i>, identical to EL lamp <b>28</b>, for illuminating the electrical switches <b>27</b> on the flip pack <b>18</b> in the opened position. The flip cover <b>24</b><i>a </i>may be held in the opened position by the action of a detent (not shown).

While the invention has been illustrated by the description of one or more embodiments thereof, and while the embodiments have been described in considerable detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of Applicants' general inventive concept.